Suspension Problems of Toyota FJ Cruiser - part 1

Please consider opening or expanding an investigation into frame, underbody, brake-line, and suspension-mount corrosion affecting Toyota Fj Cruisers. I own a 2013 Toyota Fj Cruiser 4wd. A professional inspection found multiple fluid leaks, heavy rust, rusted exhaust, leaking rear shocks, and brake line/hose concerns. After reviewing the condition, the mechanic essentially declined to repair it and recommended scrapping the vehicle. The attached photos show conditions that appear safety-relevant: rust perforation through underbody structural metal near a bracket/crossmember area; severe corrosion around brake lines and fittings; widespread scaling near suspension and frame components; a leaking rear shock; and badly deteriorated exhaust connections. This is not just appearance rust. Also note the contrast between the observable condition of the vehicle versus the problems hidden beneath. This rust is clearly outpacing normal wear and tear. The safety risk is straightforward. At interstate speeds, a corroded brake line could fail during emergency braking. A weakened shock mount, suspension bracket, or crossmember could fail when the vehicle hits a pothole, uneven bridge plate, or highway debris. In dense, aggressive traffic, especially where vehicles travel 70+ mph, any sudden loss of braking, stability, or rear-end structural integrity could cause a spinout, rollover, or multi-vehicle crash. I understand Toyota has previously addressed severe corrosion on other truck platforms. I urge NHTSA to review whether the Fj Cruiser has a similar pattern of premature or excessive structural corrosion. Owners may not know the vehicle is unsafe until a mechanic refuses repair or a component fails. Please review consumer complaints, inspection photos, and corrosion-related failures before this becomes a fatal incident.

See all problems of the 2013 Toyota FJ Cruiser 🔎.

Frame is rusted to the point of failure.

See all problems of the 2007 Toyota FJ Cruiser 🔎.

I purchased my beloved 2013 Fj Cruiser from wellesley Toyota 6. 5 years ago and have really enjoyed it. I have had it serviced religiously at mcgee Toyota of hanover since my purchase and expected to continue to enjoy it for many years to come and was just informed by mcgee Toyota that the frame is severly rusted out throughout. My truck only has 158k miles on it and I expected this to last at least twice as long. This appears to be the same issue Toyota experienced with the tundra and tacoma with premature rusting on their vehicles due to a manufacturing issue. There are numerous complaints online about this issue and even a current class action lawsuit. I have alerted Toyota corporate of this and they are not standing behind their product.

Chassis frame rotted.

See all problems of the 2008 Toyota FJ Cruiser 🔎.

My Fj Cruiser has terrible rust on the frame. It literally looks like it was stored in the ocean for 50 years. This vehicle is from 2007 and should not have this much rust.

The Fj Cruiser is a common issue for rot/ rust on the frame of the vehicle, I have clean the frame often during the winter months and my frame is continuously rusting and rotting the frame of the vehicle I have decided to not drive the vehicle till the frame is either replaced or repaired due to the safety concern of driving it on the road, numerous others have same incidents of the holes in the frame due to rust the manufacturer did not put any kind of corrosion treatment on the frame to stop this from happening the frame flexes when accelerating and is not safe for anyone to including my passengers or other people on the road.

Frame and undercarriage have excessive wear for age of vehicle despite normal maintenance and care. Rust and corrosion has made the vehicle unsafe to drive.

Excessive frame rust causing safety issue with suspension and crash danger. Yes my vehicle is available for inspection. My safety as well as other drivers safety are put at risk if the suspension fails causing my vehicle to veer into on-coming traffic. The problem is on going and can be confirmed by a dealer or independent service. My vehicle has not been inspected by the manufacturer, but is available for inspection upon request. No warnings lamps. This is an undercarriage issue that is hidden by the tires and the body that sits on the frame.

See all problems of the 2014 Toyota FJ Cruiser 🔎.

Took vehicle to a machine shop to have frame undercoated. The machinist found that the frame had holes in it due to rust. He found that the tab gusset bracelet was cracked ( the part of the frame that holds the a-arm in place). He said that the vehicle was not safe to drive and needs a new frame. The vehicle has 109,000 miles on it. Toyota should have a recall on all Toyota fj. I contacted Toyota and was denied any help in this matter.

See all problems of the 2012 Toyota FJ Cruiser 🔎.

Our 2007 Fj Cruiser when brought in for annual inspection has been deemed unsafe for use due to crack in frame due to corrosion. The vehicle has no other mechanical issues and runs as if new. We invested in 5 new tires and now find ourselves possibly having to purchase a new vehicle. We witnessed all the other Toyota vehicles frames being replaced due to the recall regarding insufficient undercoating and excessive rust. We inquired if our vehicle was included and if there was reason for concern and were told no. We also own a 2010 prius which we purchased new. We had no reason to question the validity of the answer. Years later we are grateful we did not experience any incident and crack was discovered before one happened. We now want to know why we did not get a replacement as did all the other models.

The brakes are constantly binding up due to rust and need replaced, recently abs brake lines rusted off causing me to miss a stop sign, very dangerous, upper rear control arm mount rusted and cracked completely off causing steering and braking problems and had to be replaced to even use this vehicle, , the front rack has been replaced due to excessive rust of lines and fittings, same with transmission cooler lines-rotted off. . . Brake backing plates rotted off. . Even though I have had this undercoated and rust treated, the frame is rusting inside-out. . . Frame braces, everything on the frame is rusted much more than one would expect, even in a salt state like ohio. . . . My safety was put at risk by faulty brakes, the frame is not safe under hard braking and may cause an accident, the dealer has seen this vehicle, a local independent says "get rid of it". . . No warning lamps, just wild things happen with brakes, pulls left, pulls right, front, then back and this past time . . . None!. . . Only 111,000 miles.

The frame and associated components are severly corroded putting the vehicle in danger of the back axel detaching . I was informed of this by a repair shop who were concerned of the safety of operating vehicle. There is some type of coverage for related vehicles but not for this model. I think this is the same platform which was recalled under a truck model. Toyota refuses any coverage or help for this problem. The vehicle has 70k miles but is unsafe to operate. Photos are available. Although the top of the vehicle is what you would expect with 70k miles, it is unsafe to operate because the back axel could fall off at any time.

Backing out of my driveway we heard a slight pop and a dragging feel on the right passengers front. ( thought I ran over a landscape brick) stopped and inspected nothing was under the vehicle starting to leave my complex vehicle started to shake some. When I got up to 20 mph it was obvious I should not drive. Called tow truck. Thought I needed ball joints or something similar. Mechanic said frame was completely rusted out and unfixable. The Toyota Fj Cruiser is suppose to be a tough off road SUV which I never used for off road driving they even advertised how tough the frame is in commercials . I see there has been recalls for other Toyota models of SUV and trucks of the same year and their is a class action lawsuit already started I think in California. If I would have continued to the freeway a serious accident would had happened. I contacted Toyota and opened a case # 221011002195 which after two communications they closed because there is no recall on the vehicle. The car is in great condition other wise. A frame should last more than 15 years on a truck \SUV designed for off road driving . Her are some details of the pending lawsuit: plaintiffs allege that a manufacturing defect causes excessive rust and corrosion to the frames of 2007-2014 Fj Cruiser vehicles. The suit claims the defect weakens the structure of the vehicle, therefore posing a serious safety threat to vehicle occupants. In some cases, vehicles failed to pass safety inspection and are no longer safe to drive. As a result, owners find themselves stuck with a vehicle that is no longer legally allowed on the roads with a greatly diminished resale value. Toyota activity marketed the Fj Cruiser with special “electrocoat deposition” rust protection coating despite Toyota’s marketing highlighting the “electrocoat deposition” protective coating, plaintiff’s claim Fj Cruiser frames prematurely rust and corrode at an accelerated rate. The suit states Toyota had been aware of the frame defect, but fail.

Frame rust has become a major safety issue even though we do rust prevention twice a year.

Massive amounts of rust underneath the car on the frame and pretty much everything is affected around it. Concerned for my families safety…Toyota needs to address this immediately!!!.

After buying my vehicle I have began to notice a growing rust problem that is not due to salt water or other environmental conditions, but clearly a defect in manufacturing. After joining a few facebook groups with other fj owners I’ve found countless other people have had the same problem and that without massive trust removal my vehicle is expected to have failures in the frame and suspension at some point.

I went down the road & hit a bump my car rocked a little so I stopped to check the lug nuts & see if anything was wrong. I did not see anything. So, I continued to go pick my friend up as I was driving down the freeway anytime I hit a bump the car rocked more the faster I went. So I slowed down & watched traffic around me. Picked my friend up, went on the ramp and hit another bump and bam, my vehicle went so high up in the air my friend thought we were going to roll over. I immediately got off the freeway & there was a dealership right there. I asked if they could look at it & they wouldn't, they were too busy. I managed to baby it all the way back to my dealership. They said the control bar came away from the frame that was rotted. I called my insurance CO. They said nothing they could do because of wear & tear. They did not view anything but pictures. I called claims & they said my VIN has no recalls that they won't do anything. They did not look at anything. I asked that they call my dealership to have them tell them how serious this could have been. They said my warranty was up in July of 2021. I had no letters to tell me this. I have only had it serviced at the dealership when it was due for service, nowhere else. I found out claims previously have been paid through a lawsuit on frames. Frames should last longer than this even in inclement weather. I also had it fluid filmed. Nobody will do anything & it's scary. Sad they want an accident before they look at things. I hope you can address this some way. Thank you.

Frame is rusting out.

Frame rust. Gas tank strap rust. Undercarriage rusted.

I purchased the vehicle with a clean carfax on 12/2/2021 flew from phoenix to dallas to pick it up. Drove the vehicle from dallas to phoenix. The brakes malfunctioned on the drive home. Fortunately it was late at night and not many vehicles on the road. Took car to mechanic on 12/4/2021. The frame, brakes, suspension, exhaust and engine mounts had been sprayed over to cover severe rust and rot of the the frame and undercarriage. The vehicle cost 14k the repairs to be done 20k the vehicle is not roadworthy and has not been driven since ai got back to phoenix. The dealership purposely didn’t disclose the frame or brake damage. The dealership sold this vehicle knowing it was for my daughter and 3 year old granddaughter.

Undercarriage of vehicle was not properly rust coated by manufacturer. Undercarriage is so rusted that my mechanic advised it may need a new frame.

Frame rust all over, going to cost tons of money to fix. Rust rotting through the frame of the car. Shouldn’t be a problem dont live near water or salt area.

My recently purchased Toyota Fj Cruiser was found to have severe rust underneath the car . Nuts and bolts have rotted away with the part now held together by rust weld. New straps are holding up a dented gas tank which my mechanic thinks fell when the original straps failed. Is it a safety issue when a gas tank falls off a traveling vehicle? I don’t know what other problems may arise from this, but I have been online and there seems to be complaints of this nature all over the internet. Toyota ordered a recall on several models for this problem, but not the fj. This many people can’t be making this stuff up. At some point it is going to lead to a death, if it hasn’t already . Have only had this vehicle 2 weeks, and I find it hard to believe Toyota can’t address this problem like it did with other models of their fleet. One lady’s pickup bed almost separated from the front of the truck. Please use whatever tools you have to see that Toyota does the right thing, and takes care of the customers who are driving their vehicles.

I was driving down the street after filling up my fuel tank. I drove approximately 1/2 mile when I heard a sound, felt a clunk and stopped immediately. My fuel tank was hanging down on the ground. I called aaa and requested a flatbed and to bring a strap. He did not bring a strap and when my truck arrived at the mechanic the fuel tank had completely separated from the vehicle. The other complaint I have is the rusted frame. I purchased this vehicle used. I did not notice that the tube before the rear axle which holds suspension supports to the frame were completely broken off and separated from the rusted out frame that has failed. It has been welding but the rusted frame is very difficult to weld to.

Excessive rust on frame components from inside frame rails. Failure of suspension mounting points at the rear axel. Failure of the rear cross member and hitch due all due to excess rust.

Too much frame rust on vehicle. Rust seems to be most prevalent around welds where cross members meet the frame. This frame is the same frame used for a number of other Toyota vehicles. In some places the rust is nearly bad enough for crucial body members to separate which would cause a severe accident. The frame on the Toyota Fj Cruiser is the same frame used in the vehicles outlined in the successful class action lawsuit, "brian warner et al. V. Toyota motor sales, u. S. A. , inc. " in the united states district court for the central district of California case no. 2:15-cv-02171-fmo-ffm. That lawsuit only specified Toyota tacoma, tundra, and sequoia vehicles though the frames are the exact same. My frame is still under warranty.

Rust! frame rust!.

The contact owns a 2007 Toyota Fj Cruiser. The contact stated while getting an oil change, the contact noticed that rusting to the undercarriage and the sub frame had caused the driver’s side rear axle bracket to fracture. The vehicle was not taken to a local dealer nor an independent mechanic to be diagnosed. The vehicle was not repaired. The manufacturer was informed of the failure and a complaint was filed. The failure mileage was approximately 156,350.

My vehicles frame/ suspension has deteriorated to the point the Toyota dealer wont pass it for safety inspection. The frame and suspension have disintegrated. This truck has been garage kept since new and is in otherwise perfect condition.

The frame has rusted out based on recent inspection at the Toyota dealership. It poses a safety concern.

The contact owns a 2010 Toyota Fj Cruiser. The contact stated while driving at various speeds over speed bumps, the vehicle would shake abnormally and was not stable while driving. The contact stated there was no warning light illuminated. The vehicle was taken to an independent mechanic where it was diagnosed with the rear axle needing to be replaced. The vehicle was repaired. The manufacturer had not been informed of the failure. The failure mileage was approximately 66,731.

See all problems of the 2010 Toyota FJ Cruiser 🔎.

I purchased the car from an individual on Dec. 12, 2020. Less than 30 days ago. I brought it to the body shop to see if they could fix the rattling sound that came from when I hit a bump. The cars body is in great condition. The mileage when I bought the car was 183,800. I assumed I may need to do some work on the car, but the body shop told me that the sound I was hearing was different parts of the undercarriage that had rusted so badly that they where close to falling off. Including the gas tank. They told me that Fj Cruisers where known for rusty under bottoms and that I would be a safety risk to myself and others if I drove the car. They also said the car was beyond normal repair. I will attached photos they sent me. I have driven the car 1,500 miles and it is considered undrivable and unfixable. I got a second opinion. Without knowing the results of the first opinion they came to the exact same conclusion. Except they told me to reach out to you.

Severe suspension bracket rust on multiple rear and front components. I luckily was able to avoid an accident when braking but my entire car swayed when the rear lateral support bar bracket broke right off the mount that is welded to the rear due to rust. I then inspected and found multiple rust areas on frame and other suspension brackets. Making this vehicle unsafe to drive. I am aware of Toyota's ongoing dilemma with using this horrible untreated steel and hope the NHTSA addresses this issue. This is not normal corrosion this is an absolute neglect in safety by not having this steel treated on such critical components of a vehicles frame. Had this incident happen on the highway at speeds of 55 mph or greater. Serious injury and/or death can occur. If I am not the only consumer having this issue on Toyota fj crusier vehicles. I hope the NHTSA enforces a recal on these frames and/or critical suspension components. My vehicle is 16 years old, I purchased it from a dealer whom recieved it from the original owner with 57,000 miles on it. Now currently after 4 years of owning this Fj Cruiser I only have 71,000 miles on it. Had this bracket caught onto my brake lines which is located directly below this rear bracket I would have lost all ability to stop my vehicle.

My son was driving home from school when he heard a rattle/bang when he took a corner or went over a bump. He told me about the noise as soon as he got home. We took the fj out for a drive and I heard the noise coming from the driver's side. Upon inspecting the exterior drivers side I found that the left side, rear trailing arm mounting point and a section of the fj's frame, had torn away from the frame. The trailing arms was not floating, unattached. We are very luck that the trailing did not drop while my son was driving home, as it would have been driven into the pavement, possibly causing a catastrophic accident. I have called Toyota corporate, who can provide not solution on how to repair this issue. Again, I am lucky my son was on secondary roads and not the highway and the trailing arm fell to the pavement.

Gas tank straps broke frame deteriated on fj crusier with only 72000 miles on it would have never known how unsafe frame is if straps gas tank hanging.